Apparatus and method for producing four piece lead wire assemblies

ABSTRACT

Apparatus and method for simultaneously producing four piece lead wire assemblies during which a plurality of wires are fed at varying intervals to a rotating turret as it revolves through a series of three work stations and one idle station. At the first work station, a first lead wire is fed into the turret where it is clamped by a clamping means located within the turret. A cutter then cuts the first wire after which this newly formed first piece is rotated to the second work station wherein a second wire is fed, cut, and bonded to one end. This joined assembly is then rotated to the idle station where, after a predetermined time interval, it is rotated to the third work station. Here, a third wire is fed, cut and joined to the unbonded end of the second lead. During this same time period, a fourth wire is fed, cut, and joined to the unbonded end of the first lead. The entire four piece lead wire assembly is then ejected from the turret into a receiving magazine.

United States Patent Alexander et a1.

[ 1 Mar. 27, 1973 APPARATUS AND METHOD FOR Assignee:

Inventors: Robert H. Alexander, Russell;

E. Ballard, North Warren, both of Pa.

(iTlij sj'lvania Incorporated, Seneca Falls, N.Y.

Sept 14, 1971 Appl. N0.: 180,313

US. Cl. ..29/2s.19, 140/112, 29/628 1m. (:1 ..H01j 9/46 Field of Search ...74/436, 813, 822, 824,, 820;

29/628, 25,19,37 R, 33 J, 355, 36, 39, 628, 203 MW, 49, 53, 430, 25.1; 140/111-113,

References Cited UNITED STATES PATENTS 2,579,117 12/1951 Kremer ..140/112 Primary ExqminerCharles W. Lanham Assistant Examiner-D. C. Crane Attorney -Norman J. OMalley 1571 ABSTRACT 'Apparatus and method for simultaneously producing four piece lead wire assemblies during which a plurality of wires are fed at varying intervals to a rotating turret as it revolves through a series of three work stations and one idle station. At the first work station, a first lead wire is fed into the turret where it is clamped by a clamping means located within the turret. A cutter then.cuts the first wire after which this newly formed first piece is rotated to the second work station wherein a second wire is fed, cut, and bonded to one end. This joinedassembly is then rotated to the idle station where, after a predetermined time interval, it is rotated to the third work station. Here, a third wire is fed, cut and joined to the unbonded end of the second lead. During this same time period, a fourth wire is fed, cut, and joined to the-unbonded end of the first lead. The entire four piece lead wire assembly is 8 Claims, 21 Drawing Figures PATENTEDMRZYIBB SHEET 10? 6 INVENTORS. ROBERT H. ALEXANDER &

PAUL E. BALLARD ATTORNEY PATEmEnulmzvma SHEET 2 BF 6 III INVENTORS,

ROBERT H. ALEXANDER 8.

AUL E. BALLARD ATTORNEY PATH-HEDHARNIQYS 22,0455

SHEET 3 0F 6 INVENTORS ROBERT H. AL

1 PAUL E. BALLARD ATTORNEY EXANDER8" SHEET HlF 6 INVENTORS ROBERT H. ALEXANDER&

PAUL E. BALLARD ATTORNEY PATENTEUMRZYISB 722 045 SHEET 5 OF 6 INVENTOR. ROBERT H. ALEXANDER &

BY PAUL E. B'ALLARD COW 2. w

ATTORNEY PATENTEUHARZTIQYS SHEET GDP 6 APPARATUS AND METHOD FOR PRODUCING FOUR PIECE LEAD WIRE ASSEMBLIES BACKGROUND OF THE INVENTION This invention relates to apparatus and methods for producing multipiece lead wire assemblies and more specifically to an apparatus and method for producing four piece lead assemblies for electric lamps.

Lead assemblies as produced by methods of the prior art are most usually of the three piece variety. To

manufacture an assembly of this type, the standard procedure is to retain one of the pieces, termed a central piece, and abut two additional pieces to it, one to each end. These two pieces are most usually fed laterally from opposing directions until they contact the opposing ends of the central piece, whereupon the bonding is accomplished. To add an additional piece to the three piece assembly necessitates a hand bonding operation, thus involving the possibility of human error. In addition, manual alignment of the pieces to complete this final operation haas proven excessively time consuming.

OBJECTS AND SUMMARY OF- THE INVENTION It is, therefore, an object of this invention to provide a new apparatus and method for producing multipiece lead assemblies.

It is a further object of this invention to provide a new method and apparatus for producing lead assemblies of this variety for electric lamps.

It is a further object of this invention to provide an apparatus which automatically produces lead assemblies as described above having four different pieces of lead wire bonded therein.

The foregoing objects are achieved in one aspect of the invention by an apparatus which provides four piece lead assemblies through the agency of supplying a plurality of lead wires to a rotating turret during predetermined intervals as the turret revolves through three work stations. Located within the turret are a plurality -of clamping means, each being adapted for clamping a first wire at a first work station. This wire is then cut by a cutting means and a means for rotating the turret rotates the severed piece to the second work station. Here, means for supplying, retaining, cutting, and bonding are engaged to join a second piece to the clamped first piece. The turret is now rotated to the third work station wherein means for supplying, retaining, cutting and bonding are engaged to join a third piece of wire to the unbonded end of the second piece. Concurrent with this step, additional means for supplying, retaining, cutting, and bonding are engaged to join a fourth piece of wire to the unbonded end of the first piece. Once assembled, the lead assembly is removed from the turret by an ejection means. I

Further objects are achieved in another aspect of the present invention by a method for producing four piece lead assemblies in which a first lead wire is clamped in a rotatable turret at a first work station. The wire is then cut and the turret is rotated to a second work station wherein a second wire is fed, cut, and bonded to the first piece. These joined pieces are then rotated to a third work station wherein third and fourth wires are fed from opposing directions, each of these then being clamped, cut, and bonded to the unbonded ends of the joined second and first pieces, respectively. The joined four piece lead assembly is then ejected from the turret.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an end elevational view of the present invention.

FIG. 2 is an end elevational view of the present invention similar to FIG. 1 showing rotation of the drive apparatus and the consequential effect on the turret.

FIG. 3 is 'a-plan view of the present invention as taken along the line 3-3 in FIG; 1.

FIG. 4 is a plan view of the present invention as taken along the line 4-4 in FIG. 2.

FIG. 5 is an elevational view, in section, of the turret as taken along the line 5-5 in FIG. 3.

FIGS. 6-10 are elevational views, in section,,showing the relative positions of the internal components of the turret as the turret is rotated through the three work stations, the idle station, and finally to the point of ejection.

FIGS. 11-17 are isometric views of the turret and adjoining components which feed, retain, bond, and cut the first two wires for one lead assembly.

FIGS. 18 and 19 are elevational views showing the procedure for joining the last two wires to the lead assembly, this occurring at the third work station.

FIG. 20 is one example of a lead assembly as produced by the present invention, and

FIG. 21 is an elevational view of an incandescent lamp, in which can be utilized the lead assemblies as produced by the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS For a better understanding of the present invention, together with other and further objects, advantages, and capabilities thereof, reference is made to the following disclosure and appended claims in connection with the above-described drawings.

With reference to the drawings, in FIG. 1 there is shown an end elevational view of apparatus 11 for manufacturing multi-piece lead assemblies. Rotating turret 13, affixed to a first rotating shaft 15, comprises a plurality of clamping means 17 substantially equally spaced about the external edges of the turret. The operation of these clamping means will be explained in greater detail in the description of FIGS. 5-10. The purpose of turret 13 is to receive and clamp a first lead wire at a first work station, where it is cut and rotated to two other work stations wherein the rotation of the turret is delayed while other pieces are bonded to form a leadassembly. Between the second and third work stations the turret also stops for a predetermined interval at an idle station. To give the turret this intermittent rotation, a channeled cam member 19 is also positioned on first rotating shaft 15 and comprises a plurality of channels 21 formed therein. As wheel 23, positioned on second rotating shaft 25, is revolved in the direction indicated, pin 27 engages one of channels 21 causing channeled cam member 19 to rotate, this movement in turn causing rotation of turret 13. When wheel 23 has revolved a distance sufficient to cause disengagement of pin 27 from channel 21, motion ofmember 19 is stopped. To assure alignment of one of channels 21 for accepting pin 27 upon the next complete rotation of wheel 23, adjoining cam 29 is also positioned on second rotating shaft 25 and has its external surfaces adapted for aligning with and engaging the contacting external surfaces 33 of channeled cam member 19.

Accordingly, rise portion 31 of adjoining cam 29 mates with one of surfaces 33 of cam member 19 during pin disengagement. When pin 27 is engaged in channel 21, fall portion 32 of adjoining cam 29 is designed to clear the non-contacting external surfaces 34 of cam member 19. The cleared position is best shown in FIG. 2.

To drive wheel 23 and adjoining cam 29, first gear 35 is positioned on second rotating shaft 25 and mates with second gear 37 positioned on drive shaft 39, this shaft in turn being driven by motor 41 using belt 43.

In FIG. 2 is shown the partial rotation of the turret as it leaves a position adaptable for receiving lead wires as illustrated in FIG. 1 and rotates to the next station.

In referring to both FIGS. 1 and 2 there are shown the several external components necessary for the operation of clamping means 17 of turret 13. These comprise anactuating cam 45 positioned on third rotating shaft 47 which is also driven by motor 41. Engaging the external surface 46 of cam 45 is follower wheel 49 which is attached to pivoting lever 51, having its pivot position 53 established as shown on wall 55. Rotation of cam 45 therefore causes movement of lever 51 to in turn move linkage arm 57 to actuate end member 59, this member being positioned on fourth rotating shaft 61. Positioned on the other end of shaft 61 and also within turret 13 is a movable cam 77, shown in FIG. 3, which actuates each of the clamping means 17. Fourth rotating shaft 61 is concentrically aligned within first rotating shaft 15. To assure that follower wheel 49 on pivoting lever 51 remains against external surface 46 of cam 45, spring 63 is attached as shown to lever 51 and stationary rod 65.

To more clearly illustrate the positioning of the components previously described, reference is hereby made to FIGS. 3 and 4. FIG. 3, taken along line-3-3 in FIG. 1, shows turret 13 positioned on first rotating shaft 15. Also positioned on shaft is channeled cam member 19 having channels 21 located therein, each adapted for receiving pin 27 on wheel 23 as the wheel turns in the direction indicated. Wheel 23 is positioned on second rotating shaft 25 as are adjoining cam 29 and first gear 35. Supports 67 and 69 affixed to wall 55 serve to support and maintain shaft 25 in alignment. Support 67 also aids another support (not shown) in aligning first rotating shaft 15. In like manner, supports 71 and 73 support and maintain alignment of third rotating shaft 47 on which is positioned actuating cam 45. Positioned directly below shaft 47 and hidden from the sight of the viewer in FIG. 3 is drive shaft 39 which is also supported andretained in alignment by similar type supports, as can more clearly be seen in FIGS. 1 and 2.

Second gear 37 is positioned on the end of shaft 39 and is shown to align with first gear 35. Belt 43, driven by motor 41, drives pulley 75 positioned on. third shaft 47 to provide means for rotating cam 45. Belt 43 also serves to drive second gear 37 as was shown in FIGS. 1 and 2.

In FIGS. 3 and 4, the positioning of the external components for actuating the movable cam 77 are also more clearly shown. This cam, as previously explained,

is affixed to one end of fourth rotating shaft 61, this shaft concentrically aligned within first rotating shaft 15 and has end member 59 affixed at its other end. Linkage arm 57 is joined to end member 59 at one end and pivoting lever 51 at the other. Follower wheel 49 is shown to ride on the outer surface of actuating cam 45.

With particular reference to FIG. 4, the partial rotation of first rotating shaft 15 is shown, resulting from the engagement of one of channels 21 with pin '27 as wheel 23 has rotated.

The positioning of the internal components of turret 13 are illustrated in FIG. 5, relative to the position of apparatus 11 as shown and described in FIGS. 1 and 3 respectively. FIG. 5, as taken along line 5-5 in FIG. 3, shows clamping means 17, in this case four, as they are positioned about turret 13.

Each ofclamping means 17 comprises'a sliding jaw 79 which moves within channel 81 within turret 13, and a stationary jaw 92. Pivotal arm 83 pivots about point 85 and has a first extension member 87 having a fol-, lower means 89 located thereon. A second extension member 91 of pivotal arm 83 is pivotedly attached to sliding jaw 79-. Accordingly, it can be seen that as movable cam 77 is rotated in the direction shown as a result of the motion previously described in FIGS. 1 and 2, the rise portion 86 of cam 77 engages follower means 89 to in turn move sliding jaw 79 in a direction away from the stationary jaw 92. In doing so, this clamping means is thereby opened and adaptable for receiving a first lead wire, thus making this position on the turret the first work station 90.

To assure that follower means 89 of this and the other clamping means remain firmly against the entire contacting surface of movable cam 77 throughout rotation of turret 13, spring loaded pistons 93 positioned within corresponding cylinders 95 are provided to continually exert force against each of first extension members 87 of pivotal arms 83. As first lead wire 97 is supplied to turret 13 at first work station 90, sliding jaw 79 is moved in a direction toward stationary jaw 92 to thereby clamp this wire, this movement shown in FIG. 6 and resulting from the rotation of movable cam 77 as indicated.

In referring back to FIG. 1, it can be seen that with every 90 rotation of turret 13, actuating cam 45 is rotated a full cycle, or 360, thereby causing movable cam 77 to return to the position shown in FIG. 5 as each clamping means 17 reaches first work station 90. This movement allows for a continuous feed of one first lead wire to the turret at work station 90-for every 90 turret rotation, thereby making every clamping means 17 functional to the operation of the apparatus. To simplify description of the turret operation however, reference will be only made to first wire 97 as it proceeds through the cycle of operation.

In FIG. 7, first wire 97 has been cut to form first piece 97a and is now moved to second work station 100 whereupon a second lead wire is supplied, cut, and bonded to one end of first piece 97a, creating first assembly 98. (See FIGS. 13-15). At the same time another first wire 97 is supplied and retained at first work station 90.

In FIG. 8 first assembly 98 is rotated to idle station 101 for a predetermined delay and then to a third work station 103, shown in FIG. 9. Idle station 101 is termed so because no operations are performed on assembly 98 at this position, the reason being that the design of apparatus 11 is such that the positioning of external components in the immediate area surrounding station 101 is somewhat restricted, as can be seen with reference once again to FIGS. 1-4.

At third work station 103, a third lead wire is supplied, cut, and joined to the unbonded end of the second piece (see FIGS. 18 and 19) while a fourth piece of lead wire is supplied, cut, and joined to the unbonded end of first piece 970. The joining of the second, third and fourth pieces to complete the lead assembly will be more clearly shown in the description of FIGS. 13-19. 7

FIG. 10 shows the position of turret 13 as the bonded lead assembly is ejected. As clamping means 17 approaches this position, an ejection arm 105 attached to and driven by an air drive means 107, is swung in the direction shown. A notched portion 109 in ejector arm 105 aligns with and engages the lead assembly, thereby removing it from the clamping means, which in turn has been opened as a result of follower means 89 engaging rise portion 86 of cam 77. The bonded lead assembly is caught in a receiving bin (not shown) and ejector arm 105 is returned to its original position prior to ejecting the assembly. Air drive means 107 comprises an air cylinder 110 having a piston 111 fitted therein, the

I 98 to idle station 101 and then to third work station piston being joined to ejector arm 105. To move arm 105 in the direction shown, air is fed into air cylinder 110 in the direction indicated. To return arm 105 to its original position, the air supply is reversed, thus moving piston 1 1 1 in the opposite direction.

FIGS. 11-19 more clearly illustrate the various steps necessary to complete one of the lead assemblies. In FIG. 1 1, first spool 113 supplies a length of lead wire 97 to clamping means 17 at first work station 90. Sliding jaw 79 moves toward stationary jaw 92 and clamps lead wire 97. A first cutter 117 severs lead wire 97 to form first piece 97a, this occurring in FIG. 12. The movements of the components for supplying cutting, and bonding the lead wires as shown in FIGS. 11-19 are controlled by a timed multiple cam program, each cam respectively designated to actuate a corresponding component. Because several other control means are possible for accomplishing these movements, it is not felt necessary to describe their control in any greater detail. One typical example of another control means could comprise a predetermined electronically controlled program operating in conjunction with a multiple switching array, each switch programmed to actuate a designated component.

First piece 97a is next rotated to second work station 100, shown in FIG. 13, where a second spool 119 supplies a second length of lead wire 121 which is retained by first bonding arm 123 as it contacts the end of first piece 97a. Contactor member 125 is moved into position to contact the opposing open end of first piece 97a after which second cutter 127 closes to sever second length of lead wire 121, this occuring in FIG. 14.

In FIG. 15, first piece 97a and newly formed second piece 129 are bonded together to form first assembly 98. In the embodiment as shown, welding is the preferred method of accomplishing this bonding, with electrical current being supplied bonding arm 123 while contactor member 125 acts as a ground. The high 103, respectively. At third work station 103, theremaining two pieces of lead wires are bonded. FIGS. 18 and 19 best explain the movements of the components required to complete this final bonding. In FIG. 18, taken along line 18-18 in FIG. 17, a third length of wire 133 is supplied from third spool 135 and engages the unbonded end of second piece 129. At the same time, a fourth length of lead wire 137 is supplied from fourth spool 139 and engages the unbonded end of first piece 97a. Bonding arms 141 and 143, both substantially similar to bonding arm 123 in FIGS. 13-15, move upward to respectively retain third length 133 and fourth length 137 of the lead wires. Concurrent with this move, contactor arm'145 moves to contact second piece 129. Upon completion of these move ments, third cutter 1.47 and fourth cutter 149 close to sever third and fourth lengths, 133 and 137, respectively. When both lengths have been severed, electrical current is supplied bonding arms 141 and 143 with contactor arm 145 acting as ground. This produces a bond between second piece 129 and newly formed third piece 151 and a bond between first piece 97a and newly formed fourth piece 153, thereby producing a bonded four piece lead assembly 155, shown in FIG. 20.

One primary example for using lead assemblies of this type is shown in FIG. 21. Here an electric lamp 157 of the incandescent variety is shown to comprise a base 159, a stem press 161, a filament 163 and a glass envelope 165 Two lead assemblies are utilized, each having first piece 97a and second piece 129 retained within stem press 161. Third pieces 151 extend into base 159, one of which is connected to the lamps terminal 167, the other exiting between the base and envelope, while corresponding fourth pieces 153 extend to contact filament 163. As electric current is supplied the lamp through terminal 167, filament 163 becomes heated and consequently provides the source for light for the lamp, this occurrence quite common in the art of incandescent lighting. In the embodiment as shown in FIG. 21, second pieces 129 are designed to serve as fuse wires, thereby providing lamp 157 with an additional safety factor in that these pieces will melt and consequently sever, should excessive electrical current be supplied the lamp.

Thus there has been described and illustrated an apparatus and method for producing four piece lead assemblies through the agency of supplying each of the four pieces to a rotating turret member as the turret rotates through a series of three work and one idle station. The entire apparatus is completely automatic in operation, to include a means for ejecting the completed lead assembly from the turret.

While there have been shown and described what are at present considered the preferred embodiments of the invention, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the scope of the invention as defined by the appended claims.

What is claimed is:

1. A method for producing multi-piece lead wire assemblies through the agency of supplying a plurality of lead wires to a rotating turret at predetermined intervals as said turret rotates through a series of at least three work stations, said method comprising:

initially supplying a firstlead wire to said turret at a first work station wherein said first lead wire is retained and cut;

rotating said cut first piece of lead wire to a second work station wherein a second lead wire is supplied, retained, cut, and joined to one end of said first piece of lead wire; 1

rotating said joined first and second pieces of lead wire to a third work station wherein a third lead is supplied, retained, cut, and joined to the unbonded end of said second piece of lead wire, and a fourth lead wire is supplied, retained, cut, and joined to the unbonded end of said first piece of lead wire; and

ejecting said joined pieces of lead wire from said turret.

2. The method according to claim 1 in which said method of joining said lead wires is welding.

3. An apparatus for producing multipiece lead wire assemblies through the agency of supplying a plurality of individual lead wires to a rotating turret at predetermined intervals as said turret rotates through a series of at least three work stations, said apparatus comprising:

means for rotating said turret through said series of work stations whereby said rotation of said turret is delayed during said predetermined intervals at each of said work stations;

a plurality of. clamping means, each of said clamping means adapted for retaining a first of said lead wires at a first of said work stations;

means for cutting said first lead wire after said wire has been retained by said clamping means;

means for supplying, retaining, cutting, and joining a second of said lead wires to one end of said out first wire at a second of said work stations;

means for supplying, retaining, cutting, and joining a third of said lead wires to the unbonded end of said second wire at a third of said work stations;

means for supplying, retaining, cutting, and joining a fourth of said lead wires to the unbonded end of said first wire at said third of said work stations; and

ejection means for ejecting said joined lead wires" first lead wire. 5'. The apparatus according. to claim 4 in which said movable cam positioned within said turret is axially oriented with each of said follower means located on said first extension members of said clamping means, each of said clamping means being sequentially actuated by said movable cam during rotation of said turret.

6. The apparatus'according to claim 4 in which each of said follower means located on said first extension members of said clamping means comprises a movable wheel being pivoted about an axis established within said first extension member.

7. The apparatus according to claim 4 in which each of said follower means located on said first extension member is continually retained against said movable I cam by a spring loaded piston, said piston positioned within a cylinder within said turret and adapted for engaging said first extension member.

8. The apparatus according to claim 4 in whichthe shaft for rotating said movable cam is concentrically aligned within the shaft for rotating said turret.

l I! II! I i 

1. A method for producing multi-piece lead wire assemblies through the agency of supplying a plurality of lead wires to a rotating turret at predetermined intervals as said turret rotates through a series of at least three work stations, said method comprising: initially supplying a first lead wire to said turret at a first work station wherein said first lead wire is retained and cut; rotating said cut first piece of lead wire to a second work station wherein a second lead wire is supplied, retained, cut, and joined to one end of said first piece of lead wire; rotating said joined first and second pieces of lead wire to a third work station wherein a third lead is supplied, retained, cut, and joined to the unbonded end of said second piece of lead wire, and a fourth lead wire is supplied, retained, cut, and joined to the unbonded end of said first piece of lead wire; and ejecting said joined pieces of lead wire from said turret.
 2. The method according to claim 1 in which said method of joining said lead wires is welding.
 3. An apparatus for producing multipiece lead wire assemblies through the agency of supplying a plurality of individual lead wires to a rotating turret at predetermined intervals as said turret rotates through a series of at least three work stations, said apparatus comprising: means for rotating said turret through said series of work stations whereby said rotation of said turret is delayed during said predetermined intervals at each of said work stations; a plurality of clamping means, each of said clamping means adapted for retaining a first of said lead wires at a first of said work stations; means for cutting said first lead wire after said wire has been retained by said clamping means; means for supplying, retaining, cutting, and joining a second of said lead wires to one end of said cut first wire at a second of said work stations; means for supplying, retaining, cutting, and joining a third of said lead wires to the unbonded end of said second wire at a third of said work stations; means for suppLying, retaining, cutting, and joining a fourth of said lead wires to the unbonded end of said first wire at said third of said work stations; and ejection means for ejecting said joined lead wires from said turret.
 4. The apparatus according to claim 3 in which each of said clamping means located within said turret comprises: a pivotal arm having first and second extension members located thereon, said first extension member having follower means located thereon for contacting a movable cam positioned within said turret, and said second extension member being movably joined to a sliding jaw moving within a channel within said turret, said sliding jaw reacting with a stationary jaw located on said turret to retain said first lead wire.
 5. The apparatus according to claim 4 in which said movable cam positioned within said turret is axially oriented with each of said follower means located on said first extension members of said clamping means, each of said clamping means being sequentially actuated by said movable cam during rotation of said turret.
 6. The apparatus according to claim 4 in which each of said follower means located on said first extension members of said clamping means comprises a movable wheel being pivoted about an axis established within said first extension member.
 7. The apparatus according to claim 4 in which each of said follower means located on said first extension member is continually retained against said movable cam by a spring loaded piston, said piston positioned within a cylinder within said turret and adapted for engaging said first extension member.
 8. The apparatus according to claim 4 in which the shaft for rotating said movable cam is concentrically aligned within the shaft for rotating said turret. 